TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

PROCEDURE NO: 3&4ISSUE REV NO:0 NO:01 Page 1 of 21 DATE OF ISSUE:

TAPP-3&4-41150-CP-1 NUCLEAR POWER CORPORATION OF INDIA LIMITED (A Govt.of India Enterprise) TARAPUR ATOMIC POWER PROJECT-3&4

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

TAPP-3&4-41150-CP-1

Concurred BY

Name & design. NPC Design Group

PREPARED BY

CHECKED BY

REVIEWED BY

APPROVED BY

ISSUED BY

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 REVISION LOG Revision Details Issue No. Rev.No. Details Date Page No. Preparation Details Prepared by Concurred by Checked by Approved by Reviewed by

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 CONTENTS SL TITLE CLAUSE NO. Cover sheet Revision log Contents 1. Purpose Pre-requisites 2.1 Status of other systems 2.2 System Requirements 2.3 Manpower requirements 2.4 Requirement of special Equipments 2.5 Requirement of outside agencies 2.6 Hazards & precautions General method Design intents Expected process parameters Work plan Test report format Reference Verification process List of annexure----Verification requirements 1 3 5 6 PAGE NO.

2.

3. 4. 5. 6. 7. 8. 9. 10.

7 11 11 11 12 14 14 14

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1.0

Purpose: The purpose of this procedure is to provide guidelines for commissioning of the gland sealing steam system.

2.0

Pre-requisites: 2.1 a b c d e f g h i Status of other systems: All erection activities should be completed. Steam blowing/chemical cleaning of lines for auxiliary steam and sealing steam supply up to gland steam supply valve should be completed. Pipes should be normalized. Temporary supports should be removed. Steam supply from steam generators/another source is available. Area telephone & communication system inside TB, control room & switchgear is available. First Aid provision for skin burns due to hot pipes shall be available. Placards /signboards for alerting the personnel against hot pipe contact & area cordoning is required during steam blowing of the system piping. Fire fighting system / portable fire extinguishers/fire tenders are available

2.2 System Requirements

Clearance to Commission following auxiliaries:

1. 2. 3. 4. 5. 6. 7.

Turbine Sealing Steam Supply (MAW 10AA001) Leak off valve (MAW 50AA001) Gland steam supply control by pass valve (MAW 15AA001) Gland steam Leak-off control by pass valve (MAW 50AA005) Clearance to Commission Gland Steam Exhauster fans (MAW 80 AN001 & MAW 80 AN002) Drain downstream of Gland steam supply control valve MAL81 AA 001 MAW 80 AA015-Steam air mixture line valve to GSC

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 8. 9. 10. 11. MAW 80 AA016-Steam air mixture line valve to GS fans Suction valves of GS Fans MAW 80 AA 031, MAW 80 AA 032 GSC drip to FT (MAW 80 AA 005) RV (GSC RELIEF VALVE)- (MAW80 AA 011) commissioning aspect i.e. it should be calibrated to its set pressure & calibration report with QA certification shall be available. (Setting to be checked at site for calibration as per the standard check list of safety valve)

Ensure the persons working have valid certificate for working on electrical equipment.

2.3 Manpower requirements: Commissioning team (mechanical engineer -1, electrical engineer -1 & C&I engineer -1 & supporting manpower from contractor one fitter, one electrician two helpers) should be available. 2.4 Requirement of special Equipments: a. B. c. d. e. f. g. h. Oil fill for supply & leak off valves (HLP/ grade as specified) 1000V MEGGER Digital Multimeter Clamp-on meter Milli-ampere source N2 charging arrangement for N2 accumulator. Vibration meter. Direct reading contact type thermometer /non-contact type infrared thermometer.

2.5 Requirement of outside agencies a. NPCIL TG commissioning group for co-ordination. b. M/s BHEL commissioning group for execution & supervision of commissioning activities 2.6 Hazards & precautions The hydraulic units of gland steam supply & leak-off valves are equipped with positive displacement pumps. Loosening or tightening of any mechanical item should be done after depressurization of the system.

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 Gland steam condenser drain to be put to steam drain for initial period 3.0 General method a Check the completion of erection as per the design flow sheets and drawings. Check the completion of equipments and supports in gland supply steam lines & return lines. Support checking shall be certified by support checking committee of NPCIL Check for the proper identification, tagging of valves & equipment. Colour coding of painting on the pipelines shall conform the NPCIL norm T- 3&4 N-02 Check for the flow direction marking and pipe numbers for system piping. Check that the valves are installed in the appropriate flow direction by comparing with the flow direction marked in the valves. This is specifically required for supply , return valves & & check valves. Check that isolation of equipments is possible for maintenance purpose. Check electrically operated valves for electrical and manual operation. The gearbox of the valves are to be filled with oil/ grease as per manufacturers guidelines. Check the proper working/stroking of control valves as per control output /Manual signal. Check that the alarm windows are of the required colour. Check the proper wording in the alarm at the annunciation windows. Fill up the tanks through filter with the required grade of oil (HLP 46) up to normal level for valves (MAW 10AA001) &(MAW 50 AA 001). For this a funnel is to be used. Start the respective pump of individual actuators & see that pressure developed & maintained by relief valves is more than 35 kg/cm2. Otherwise, set the pressure by adjustment of relief valve. Check the N2 pressure in the accumulator. Makeup N2 if required.

d e f g h i j

TAPP-3&4 COMMISSIONING PROCEDURE

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TAPP-3&4-41150-CP-1 l Commissioning Checklist for Unidirectional Electrical Drives. (Applicable for Gland Steam Exhauster fans (MAW 80 AN001 & MAW 80 AN002)

NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

ACTIVITY Check the correctness of installation as per approved drawing. Obtain commissioning clearance in writing from competent agency Check that the equipment has been properly earthed. Check and record the insulation resistance by a meggar. Check and record the winding resistance (WR & Inductance) and nameplate details of the device. Check for the test report of the Electrical MCC Check for the correctness of overload relay setting Perform functional check of the MCC by removing the outgoing cable connections and connect back after the functional check. Issue start command from local and check for proper feedback. Check for the correctness of direction of rotation. Record the starting current of each phase Stop the device and select in remote mode. Check the interlock and protection of the device as per logic Operate the device from remote. After operating the device from remote in no load condition, keep it operating for 2-3 hrs. & note down stabilized parameters such as winding temperatures bearing temperatures current vibration If everything is all right, then load the device to full load and note down down the winding temperatures, bearing temperatures, current & vibration. Run the device for four /eight hours as per requirement and record the current in each phase at an interval of half an hour. Prepare an interim report jointly.

REMARKS

15. 16. 17.

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 m Commissioning Checklist for Electrical Actuators: Applicable for Gland steam supply control by pass valve (MAW 15AA001) Gland steam Leak-off control by pass valve (MAW 50AA005) Drain downstream of Gland steam supply control valve MAL81 AA 001 Steam air mixture line valve to GSC MAW 80 AA015 Steam air mixture line valve to GS fans MAW 80 AA016 Suction valves of GS Fans MAW 80 AA 031, MAW 80 AA 032 GSC drip to FT MAW 80 AA 005

NO.

ACTIVITY Check the correctness of installation as per approved drawing. Obtain commissioning clearance in writing from competent agency Check that the equipment has been properly earthed. Check and record the insulation resistance by a meggar. Check and record the winding resistance & inductance and nameplate details of the device. Check for the test report of the Electrical MCC Check for the correctness of overload relay setting Perform functional check of the MCC by removing the outgoing cable connections and connect back after the functional checks. Set the close and open limit switches by manually operating the actuators. Record the setting of the close and open torque switches Keep the actuator in middle position Issue open and close command from local and check for correctness of open and close direction. Since 3C-1 & 3C-2 relays are inside MCC local operation of the valves are to be dine by suitable jumpering from field JB. For this necessary jumpering details are to be worked out by C& I engineers. After the checks the jumpering is to be normalised and verified. Operate the valve for full open and full close position. Record the open and close timings.

REMARKS

Necessary/relevant document from EMU Should be available Necessary/relevant document from EMU Should be available Necessary/relevant document from EMU Should be available

10. 11. 12.

13.

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COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 14. 15. 16. Calibrate the position transmitter if available and check for the indication in the control room. Operate the actuator from remote. Prepare an interim report jointly.

Commissioning Checklist for Hydraulic Actuators. Applicable for: Turbine Sealing Steam Supply Valve (MAW 10AA001), Leak off valve (MAW 50AA001)

NO. 1. 2. 3. 4. 5. 6. 7. 8. o

ACTIVITY Check the correctness of installation as per approved drawing. Obtain commissioning clearance in writing from competent agency Check for the correct hydraulic pressure developed by the pump. Check for any oil leakage and rectify if any Feed 4-20 milli amperes from local and check for valve opening from full close condition to full open. Calibrate the valve in steps of 0%, 25%, 50%, 75% and 100% in both open and close direction. Check for any oil leakage and rectify if any Calibrate the position transmitter. Give full close to full open command from remote in steps of 10% and record the position feed back. Prepare a joint protocol. System Commissioning:

REMARKS

1st stage commissioning Stage I Steam blowing of the gland steam system downstream of G.S. supply valve Ensure that the temporary piping has been as per the steamblowing scheme.

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 Keep the gland steam supply-isolating valve (V-2401) near PRDS header closed. Install a spool piece in place of the gland steam supply valve. Ensure that isolating valve of gland steam supply valve (MAW 10 AA 511& 512) are open. Ensure that bypass isolating valve of gland steam supply valve (MAW 10 AA 001) is open Ensure that isolating valve of gland steam leak off valve (MAW 50 AA 515 & 516) are closed. The bypass valve of G.S. leak off valve (MAW 50 AA 005) is also closed. All drain lines of the gland steam system should not be connected to condenser. They are to be left to atmosphere till completion of blowing. Ensure the drain valve are open. Ensure that proper diversion of steam blowing temporary pipes has been done. Ensure that the exhaust ends of the temporary pipes are laid to a safe location Ensure that the pressure and temperature points in the pipe system is completed and the pressure points are closed and temperature points are plugged with suitable plugs. Ensure that insulation of the pipe is completed. Ensure that all temporary supports are removed and permanents supports are erected. After charging the main steam line at pressure of 20 kg/cm2 slowly open the isolating valve V 4201 and warm up of the line up to the outlet of the gland steam pipes near turbine seals for 10 min till water stops coming out through the drains Increase the valve (V-2401) opening and continue blowing of lines for 15 minutes at 20-kg/cm2 pressures.

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1
T E M P O R A R Y P IP IN G S F O R S T E A M B L O W IN G . T O B E R O U T E D T O S A F E L O C A T IO N

TURBINE

TURBINE

LP

HP

FRO M PRDS SYSTEM

TURBINE

LP

TO CO ND ENSE R

2nd stage commissioning NO. 1. 2. ACTIVITY Complete the settings in the Procontrol panel meant for Gland Steam controller as per C&I O&M manual After ensuring draining of water in the pipeline and its warm admit steam. Check for any leaks and if any get it attended. Ensure the following readiness One GS blower is in service GSC condensate valve are opened and properly vented. Condenser is ready for accepting leak off steam Fire fighting staff and facility is available Charge the pressure transmitters and ensure correct indication of gland steam pressure in control room. Operate the gland seal supply valve manually and check for change in gland steam pressure variation. Operate the leak steam valve manually and check for change in gland steam pressure variation. Note down maximum pressure and gland steam supply valve opening when steam starts coming out of turbine glands. REMARKS

3. 4.

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TAPP-3&4-41150-CP-1 5. 6. 7. 8. 9. 10. 4.0 Put the gland steam pressure controller on auto and observe the behavior of the controller. Stabilize the controller by tuning the control parameters like Proportional Gain, Integral Gain etc. Check for the change over from Gland seal supply valve to leak steam control valve during loading of the machine and vice versa. Check for the operation of Drain before Seal steam supply valve as per logic. Repeat step 7 if required for optimizing the G.S controller with TG on load Check for related alarms and annunciations in the control room Prepare an interim report jointly Design intents a
b

c 5.0

Overlap between valves (MAW 10AA001) &(MAW 50 AA 001) should not be less than 5%. Breathing of control valves should be within + 2% of stroke. Dp high across filters of (MAW 10AA001) &(MAW 50 AA 001) should appear in control room.

Expected process parameters The gland steam pressure in the header should be maintained within 0.03 + 0.005 Kg/cm2 under stabilised conditions of selfsealing or external supply steam conditions.

6.0

Work plan: a b c
d

Commissioning of electrical actuators Commissioning of Hydraulic actuators Commissioning of system in dynamic conditions.
COMMISSIONING NETWORK :

COMMISSIONING NETWORK OF GLAND STEAM SYSTEM 1 2 3 4 5 6

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1
NORMALISATION OF GLAND STEAM PIPINGS AFTER STEAM BLOWING COMPLETION OF COMMISSIONING OF ELECTRICAL ACTUATORS IN MS , HRH , CONDENSATE SYSTEM COMPLETION OF COMMISSIONING OF HYDRAULIC ACTUATORS IN MS, HRH LINES INSTALLATION OF PRESSURE AND TEMPERATURE INSTRUMENTS

COMPLETION OF FIELD CHECKS OF ALL PRESSURE AND TEMPERATURE INSTRUMENTS UP TO CONTROL ROOM READINESS OF BARRING GEAR SYSETM READINESS OF CONDENSATE SYSTEM READINESS OF CW SYSTEM STEAM GENERATOR READINESS FOR VACUUM PULLING OPERATION READINESS OF CONTROL FLUID SYSTEM VACUUM PULLING WITH GLAND STEAM AND TUNING OF GLAND STEAM CONTROLLER FOR MANUAL & AUTO OPERATION

7.0

Test report format (A) PRE-COMMISSIONING CHECKLIST FOR FANS

Equipment tag number: MAW 80 AN001 System Description: Gland steam exhauster fan P&ID No:TAPP-4/41150/5001/FS/REV NO R1 Manufacturers Name. Name Plate details

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COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 Date Sl No 1. 2. 3. 4. 5. Activity Description Bearing lubricated as recommended Rotor free in its bearings Motor checked and rotation proved Instrumentation & protection devices checked Holding-down bolts and dowels fitted securely Remarks

Fan is ready for commissioning DATA SHEET FOR FANS Start Time: TIME DATA Motor Current Vibration at Motor CE Vibration at Motor FE UNITS Amps Microns / mm/sec Microns / mm/sec Deg C Stop Time:

Temperature at Motor CE Temperature Deg C at Motor FE Legend: CE Coupling End, FE- Free End Equipment tag number: MAW 80 AN002 System Description: Gland steam exhauster fan P&ID No:TAPP-4/41150/5001/FS/REV NO R1 Manufacturers Name. Name Plate details

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 Date Sl No 1. 2. 3. 4. 5. Activity Description Bearing lubricated as recommended Rotor free in its bearings Motor checked and rotation proved Instrumentation & protection devices checked Holding-down bolts and dowels fitted securely Remarks

Fan is ready for commissioning DATA SHEET FOR FANS Start Time: TIME DATA Motor Current Vibration at Motor CE Vibration at Motor FE Temperature at Motor CE Temperature at Motor FE UNITS Amps Microns / mm/sec Microns / mm/sec Deg C Deg C Stop Time:

Legend: CE Coupling End, FE- Free End SEALING STEAM SYSTEM COMMISSIONING Sl Description No 1 Gland steam system pressure Checked OK/NOT OK Remarks

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COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 control from remote. Aux PRDS Pressure control from remote. PRDS Temperature control from remote. Change-over from MAW 80 AA015 to MAW 80 AA016 on GSC level high Opening/closing of MAL81 AA 001 on temperature interlock Tripping of MAW 10AA001 on temperature protection

2 3 4 5 6

8.0 Reference a. Turbine O&M manual b. Drawing no. TAPP-4/41150/5001/FS c. FCD For gland steam supply system

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COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 9.0 Verification process Verification process is to be carried out as per the following verification table. Activity Steam blowing Acceptance criteria As the provision no target plate can be provided, so the guideline will be blowing steam pressure (20kg/cm2), temperature (220-240 deg) & duration (20 minutes) on continuous blowing mode. Acceptance criteria would be as per MI/ED/FCD/SFD Acceptance criteria would be as per MI/ED/FCD/SFD AS per MIs of these valves & as per the design documents of GS pressure control Verification agency Engineer from TG commissioning group & as per practice of NPCIL.

Gland steam blower (fan) commissioning Commissioning of electrically operated valves Commissioning of gland steam supply and leak steam valves 10.0 List of annexure a

Verification requirements

TAPP-3&4 COMMISSIONING PROCEDURE

COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1 APPENDIX 2 VERIFICATION TABLE COMMISSIONING PROCEDURE FOR (Title)__________________ COMMISSIONING PROCEDURE NO._________________________________

SL. NO

ACTIVITY VERIFIED

ACCEPTANCE CRITERIA

VERIFYING AGENCY

CERTIFICATION BY VERIFYING AGENCY PROCEDURE VERIFICATION INSPECTION WITNESS FUNCTION -AL TEST RESULT VERIFICA -TION GENERAL REMARKS

Pl refer 4.0

Pl refer 4.0

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COMMISSIONING PROCEDURE FOR GLAND SEALING STEAM SYSTEM

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TAPP-3&4-41150-CP-1

ANNEXURE NUCLEAR POWER CORPORATION OF INDIA LIMITED (A Govt. of India Enterprise) TARAPUR ATOMIC POWER PROJECT3&4 COMMISSIONING PROCEDURE ACCEPTANCE NOTE Contractor commissioning procedure number ___________________________ for the commissioning of GLAND SEALING STEAM SYSTEM submitted by BHEL under the contract number ______________ is received and found conforming to the requirement of NPCIL specifications & Norms & hence accepted.

Commissioning procedure number: Commissioning procedure title:

_____________________________________ GLAND SEALING STEAM SYSTEM

NAME & DESIGNATION Reviewed by: Concerned Commg. Engs./ Sr.Commg. Engs/ SMEs Concerned ENCs/Suptds. Concurred by: NPC Design Group

SIGNATURE

Approved by: